seat HONDA CIVIC 2003 7.G Owner's Manual

Manual Transmission
Transmission Reassembly (cont'dl
9. Install the 14 x 20 mm dowel pins (A).
34 N.m(3.5 kgf.m,25 rbf.ft)
Set the tapered cone ring (B) as shown. Place the
transmission housing over the clutch housing,
being careful to line up the shafts.
10.
13-48
11. Lower the transmission housing the rest of the wayas you expand the 72 mm snap ring {C). Release
the snap ring so it seats in the groove of the
countershaft bearing.
12. Check that the 52 mm snap ring is securely seatedin the groove of the countershaft bearing.
Dimension O as instalted: 3.3 6.0 mm
{0.13 0.24 in.l
Apply liquid gasket (P/N 08718-0001) to the threads
of the 32 mm sealing cap {D), and install it on thetransmission housing,
Install the transmission hangers A. and B, and the
8 mm flange bolts finger-tight.
13.
't4.
15.
8 x 1.25 mm27 N.m(2.8 kgf.m.20 rbf.ft)
(t
\A
e././
Tighten the 8 mm flange bolts in a crisscross
Pattern In several steDs.
(

Special Tools Required. Boot band tool, KD-3191 or equivalent, commercially
available. Boot band pincers, Kent-Moore J-359'10 or equivalent,
commerclally available. Boot band pincers,commercially available
NOTE: Refer to the Exploded View as needed during
this procedure.
lnboard Joint Side:
1. Wrap the splines with vinyl tape (A) to prevent
damage to the inboard boot.
Install the inboard boot onto the driveshaft, then
remove the vinyl tape, Be careful not to damage
inboard boot.
Ine
4.
5
3. Installthe spider (A) onto the driveshaft by aligning
the marks (B) on the spider and the end of the
driveshaft.
Fit the circlip (C) into the driveshaft groove. Always
rotate the circlip in its groove to make sure it is fully
seated.
Fit the rollers (A) onto the spider {B) with their high
shoulders facing outward, and note these items:
' Reinstallthe rollers in their original positions on
the spider by aligning the marks (C).
. Hold the driveshaft pointed up to prevent the
rollers from falling off.
(cont'd)
@\
(u
16-11

Outboard Joint Side:
1. Wrap the splines with vinyl tape (A) to prevent
damage to the outboard boot.
Installthe new ear clamp bands (B) and outboard
boot, then remove the vinyl tape. Be careful not to
damage the outboard boot.
Install the new stop ring into the driveshaft groove
(A).3.
t
4. Insert the driveshaft (A) into the outboard joint (B)
until the stop ring (C) is close to the joint.
To completely seat the outboard joint, pick up the
driveshaft and joint, and drop them from about 10
cm (4 in.) onto a hard surface. Do not use a
hammer as excessive force may damage the
driveshaft. Be careful not to damage the threaded
section (A) of the outboard joint.
5.
10 cm(4 in.)
- ..,..,1 ;,t ,:-,;
{cont'd)
16-15

Driveline/Axle
Driveshafts Reassembly (cont'd)
Check the alignment of the paint mark (A) with theoutboard joint end (B).
7. Pack the outboard joint (A)with the joint grease
included in the new ioint boot set.
Grease quantity
Outboard ioint: 105 115 g (3.7 4.1 ozl
/r
llt ,)
\{(
-*>
:;,"0'A?g.fff :l:f '., o "o
16-16
8. Adjust the length of the driveshafts to the figurebelow, then adjust the boots to halfway betweenfull compression and full extension. Make sure theends of the boots seat in the grooves of thedriveshaft and joint.
Left driveshaft:497 502 mm (19.6 19.8in.)
Rightdriveshaft: 475 480 mm {18.7
t
-tTfi'.D.ilTD
18.9 in.l
Fit the boot (A) ends onto the driveshaft (B) andoutboard joinl (C).
9.
{

Special Tools Required. Driver 07749-0010000. Attachment,52 x 55 mm 07746-0010400. Attachment, 35 mm 1.D.07746-0030400. Oil seal driver 07GAD-PH70201
NOTE: Refer to the Exploded View as needed during
this procedure.
1. Clean the disassembled parts with solvent, and dry
them with compressed air. Do not wash the rubber
parts with solvent.
2. Press the intermediate shaft bearing (A) intothe
bearing support (B) using the special tools and a
press.
07746-0010400
Install, then seat the internal snap ring into the
groove ofthe bearing supPort.
ES
I
PR
3.
PRESS
I
4. Press the intermediate shaft (A) intotheshaft
bearing (B) using the special tool and a press.
07746-0030400
Install, then seat the external snap ring {A) into the
groove of the intermediate shaft (B).
(cont'd)
16-23

Steering
Steering Column Removal
lnstallation
1.
4.
Install the steering column, and make sure the
wires are not caught or pinched by any parts.
Insertthe upper end ofthe steering joint onto the
steering shaft {A) (line up the bolt hole (B) with the
flat portion (C) on the shaft).
8 x 1,25 mm28 N.m{2.9 kgf m,21 rbr.ft)
A
Slip the lower end of the steering joint onto the
pinion shaft {D) (line up the bolt hole with the
groove (E) around the shaft), and loosely lnstallthe
lower joint bolt. Be sure that the lower joint bolt is
securely in the groove in the pinion shaft.
Pull on the steering joint to make su re that the
steering joint is fully seated. Then installthe upper
joint bolt, and tighten it to the specified torque.
Tighten the lower joint bolt to the specified torque.
Finish the installation, and note these items:
. Make sure the wire harness is routed and
fastened properly.
. Make sure the connectors are properly connected.. Reinstallthe steering wheel (see page 17-8).
. Reconnect the battery.- Do the power window control unitreset
procedure {see page 22-128).- Enter the anti-theft code for the radio, then
enter the custmer's radio station presets.
- Set the clock.. Verify horn, turn signal switch, and cruise control
switch operation.. Check wheel alignment, if necessary (see page
18-4).. Do the engine control module (ECM) idle learn
procedu re {see page '11-139).
17-10
and Installation (cont'd){

Rack Guide Adjustment
Special Tool Required
Locknut wrench, 43 mm 07MAA-S100200
1. Set the wheels in the straight ahead position.
2. Remove the heat shield (A).
3.
9.8 N.m (r.0 kgf.m,7.2lbtft)
Remove the transmission mount bracket (see step
32 on page 13-8).
Loosen the rack guide screw locknut (A)with the
special tool, then remove the rack guide screw (B).
Remove the old sealant from rack guide screw, and
apply new sealant to the middle of the threads (A).
Loosely installthe rack guide screw on the steering
gearDox.
'-.i. '' '
07MAA-S100200
6. Tighten the rack guide screw (A)ro 25 N.m (2.5
kgf.m, 18lbf.ft). then loosen it.
5" Max.
j i-rrrr-,
I 4il N.m{a.5 kgf.m,33lbt.ft)
Retighten the rack guide screw to 6 N.m (0.6 kgf m,
4 lbf.ft), then back it off to the specified angle.
Specified Return Angle: 5' Max.
Hold the rack guide screw stationary with a wrench,
and tighten the locknut by hand until it's fully
seated.
Installthe special tool on the locknut (B), and hold
the rack guide screw (A) stationary with a wrench,
Tighten the locknut an additional 30" with the
specialtool.
Reinstall the transmission mount bracket and heat
sh ie ld,
Check for unusual steering effort through the
complete turning travel.
Check the steering wheel rotation play (see page
17-4) and the power assist (see page 17-4).
11.
7.
9.
10.
12.
17-13

EPS Components
(Motor RemovaUlnstallation (cont'dl
lnsiallation
7. Clean the mating surface of the motor (A) and
gearbox.
Apply a thin coat of silicone grease (P/N 08733-
8070E)to the new O-ring (B), and carefully fit it on
the motor.
Apply grease {Nippon Grease WR-S or equivalent
steering gear grease) into the motor shaft (C).
qE
8 x '1.25 mm20 N.m12.0 kgt.m,7 .2lbl ftl
L==-c].E@
9.
17-50
r0.Install the motor on the gearbox by engaging the
motor shaft and worm shaft (D). Note the motor
installation position {direction of motor wires).
Before tightening the bolts, turn the motor two or
three times right and left about 45 degrees. lvlake
sure the motor is evenly seated on the steering
gearbox and that the O-ring is not pinched betlveen
the mating surfaces.
Installthe removed Darts in the reverse order of
removal. and note these items:
lvlake sure the motor 2P connector is properly
connected.
lvlake sure the motor and EPS wires are not
caught or pinched by any parts.
Reconnect the negative cable to the battery.
Do the engine control module (ECM) idle learn
procedure (see page 11-139).
Enter the anti-theft code for the radio station
Dresets. Reset the clock,
Do the oower window control unit reset
procedure (see page 22-1241.
After installation, start the engine, and let it idle.
Turn the steering wheel from lock-to-lock several
times. Check that the EPS indicator does not come
on.
11.
12.
13.

EPS Components
4
17.
18.
Steering Gearbox Installation (cont'dl
Install the motor on the steering gearbox (see page
17-49).
lnstall the steering joint (A). and reconnect the
steering shaft (B) and pinion shaft (C). Make sure
the steering joint is connected as follows:
. Insertthe upperend of thesteering jointontothe
steering shaft (line up the bolt hole (D) with the
flat portion (E) on the shaft).. Slip the lower end of the steering joint onto thepinion shaft (line up the bolt hole with the groove
(F) around the shaft), and loosely installthe lowerjoint bolt. Be sure that the lower joint bolt is
securely in the groove in the pinion shaft.. Pull on the steering joint to make sure that the
steering joint is fully seated. Then install the
upper joint bolt, and tighten it to the specified
torque. Tighten the lower joint bolt to the
specified torque.
8 x '1.25 mm28 N.m{2.9 kgf.m,21 tbt.ft)
19.
20.
Installthe driver's dashboard lower cover (see
page 20-59) and under cover (see page 20-60).
lf the steering wheel was turned, center the cable
reel by first rotating it clockwise until it stops. Then
rotate it counterclockwise (about two and half
turns) untilthe arrow mark on the label points
straight up. Reinstall the steering wheel (see page
17 -8).
Install the front wheels.)1
17-66
22. After installation, perform the following checks.
. Perform the front toe inspection.. Check the steering wheel spokeangle. lfsteering
spoke angles to the right and left are not equal(steering wheel and rack are not centered),
correct the engagement of the joinvpinion shaft
serrations, then adjust the front toe by turning
the tie-rods, if necessarv.
\

Front Suspension
Knuckle/Hub/Wheel Bearing Replacement
Exploded View
Check for delormationano oamage.
SPLASH GUARDCheck for corrosion. delormation.and damage.Replace if rusted.
WHEEL BEARINGReplace.
5 mm SCREWSReplace.FLAT SCREWS6x1.0mm9.8Nm(1.0 kgf.m,7.2 lbf.ft)
BRAKE DISC
SPINDLE NUT22 x 1.5 mm181 Nm(18.5 kgf.m, 134 lbt.ft)Replace.'--7.l'tq
IAppy a small amount of engine oilto the seating surface.
lcont'd)
SNAP RING
KNUCKLE
18-11